Foam molded article

ABSTRACT

A foam molded article includes a main agent resin, a filler of greater than or equal to 15% by mass and less than or equal to 80% by mass, and a foaming agent of greater than or equal to 0.01% by mass and less than or equal to 10% by mass, and a foaming ratio caused by the foaming agent is greater than or equal to 1.1 times.

BACKGROUND 1. Technical Field

The present disclosure relates to a composite resin composition capableof realizing a foam molded article having excellent mechanicalproperties.

2. Description of the Related Art

So-called “general-purpose plastics” such as polyethylene (PE),polypropylene (PP), polystyrene (PS), and polyvinyl chloride (PVC) arenot only very inexpensive, but also easy to mold, and a weight is afraction of the weight of metals or ceramics. Therefore, general-purposeplastics are often used as materials for various daily necessities suchas bags, various packaging, various containers, and sheets, and alsoused as materials for industrial components such as automobile parts,electrical parts, and daily necessities, and miscellaneous goods.

However, the general-purpose plastics have drawbacks such asinsufficient mechanical strength. Therefore, the general-purposeplastics do not have sufficient properties required for materials usedin various industrial products such as machinery products such asautomobiles and electrical, electronic and information products, and thescope of application is currently limited.

On the other hand, so-called “engineer plastics” such as polycarbonate,a fluororesin, an acrylic resin, and polyamide have excellent mechanicalproperties, and used in machinery products such as automobiles andvarious industrial products such as electrical, electronic, andinformation products. However, engineer plastics are expensive,difficult to recycle monomers, and thus have a large environmentalburden.

In this regard, there is a demand for greatly improving the materialproperties (such as mechanical strength) of general-purpose plastics. Inorder to reinforce the general-purpose plastics, a technique ofimproving the mechanical strength of the general-purpose plastics bydispersing a natural fiber that is a fibrous filler, a glass fiber, anda carbon fiber in a resin of the general-purpose plastics has beenknown. Among them, an organic fibrous filler such as cellulose has beenattracting attention as a reinforcing fiber from the viewpoint ofinexpensive and excellent environmental properties when discarded.

In addition, as a plastic that has been reduced in weight while takingadvantage of the above-described properties, a foam molded articleobtained by adding a foaming agent into a resin and foam-molded has beenproposed.

For example, in Japanese Patent document No. 6351574, surface appearanceand impact resistance are improved by foam molding a composite resin oflow-concentration cellulose fibers uniformly dispersed in a polyamideresin.

SUMMARY

A foam molded article according to the present disclosure includes amain agent resin,

a filler of greater than or equal to 15% by mass and less than or equalto 80% by mass, and

a foaming agent of greater than or equal to 0.01% by mass and less thanor equal to 10% by mass, in which

a foaming ratio caused by the foaming agent is 1.1 times or more.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram illustrating a configuration of a foammolded article according to an exemplary embodiment of the presentdisclosure;

FIG. 2 is a schematic view for explaining a filler of the exemplaryembodiment;

FIG. 3 is a schematic view for explaining a skin layer, a core surfacelayer, and a core inner layer of the foam molded article of theexemplary embodiment;

FIG. 4 is a flowchart of a method for producing a foam molded articleaccording to the exemplary embodiment; and

FIG. 5 is a diagram illustrating results of examples and comparativeexamples in the exemplary embodiment.

DETAILED DESCRIPTION

In Japanese Patent document No. 6351574, the impact resistance isimproved by uniformly dispersing the cellulose fiber that is a fibrousfiller; however, due to the low content of cellulose fiber, the impactresistance is insufficient in a case where a resin such asgeneral-purpose plastic is used.

The present disclosure is made to solve the above problems in therelated art, and an object thereof is to provide a foam molded articlehaving weight reduction and impact resistance.

A foam molded article according to a first aspect includes a main agentresin,

a filler of greater than or equal to 15% by mass and less than or equalto 80% by mass, and

a foaming agent of greater than or equal to 0.01% by mass and less thanor equal to 10% by mass, in which

a foaming ratio caused by the foaming agent is 1.1 times or more.

Regarding a foam molded article according to a second aspect, in theabove first aspect, the foam molded article may include

a skin layer positioned on a surface;

a core surface layer positioned inside the skin layer and having a lowermass concentration of the filler than a mass concentration of the skinlayer; and

a core inner layer positioned inside the core surface layer and having alower mass concentration of the filler than a mass concentration of thecore surface layer.

In other words, regarding the foam molded article according to a secondaspect, in the above first aspect, the foam molded article may include

two skin layers; two core surface layers positioned between the two skinlayers; and a core inner layer positioned between the two core surfacelayers, in which

the mass concentration of the filler in the core surface layer may belower than a mass concentration of the skin layer, and the massconcentration of the filler in the core inner layer may be lower than amass concentration of the core surface layer.

Regarding the foam molded article according to a third aspect, in theabove second aspect, a ratio of the mass concentration of the filler inthe skin layer to the mass concentration of the filler in the core innerlayer may be greater than or equal to 1.05, and a ratio of the massconcentration of the filler in the core surface layer with respect tothe mass concentration of the filler in the core inner layer may begreater than or equal to 1.02.

Regarding a foam molded article according to a fourth aspect, in theabove second or third aspect, a cell diameter of the foaming agentcontained in the core surface layer may be smaller than a cell diameterof the foaming agent contained in the core inner layer.

Regarding a foam molded article according to a fifth aspect, in theabove second aspect, the cell diameter of the foaming agent contained inthe core surface layer may be greater than or equal to 40 μm and smallerthan or equal to 80 μm, and the cell diameter of the foaming agentcontained in the core surface layer may be greater than or equal to 90μm and smaller than or equal to 500 μm.

A foam molded article according to the sixth aspect, in any one of thefirst to fifth aspects, the filler may include a filler having an aspectratio of lower than or equal to 2 and a filler having an aspect ratio ofhigher than or equal to 10.

A foam molded article according to a seventh aspect, in the above sixthaspect, in the filler, a proportion of the filler having an aspect ratioof higher than or equal to 2 may be higher than a proportion of thefiller having an aspect ratio of higher than or equal to 10.

Regarding a foam molded article according to an eighth aspect, in theabove seventh aspect, the proportion of the filler having an aspectratio of lower than or equal to 2 in the fillers may be greater than orequal to 50% and less than or equal to 70%, and the proportion of thefiller having an aspect ratio of higher than or equal to 10 in thefillers may be greater than or equal to 1% and less than or equal to10%.

Hereinafter, the foam molded article according to the exemplaryembodiment of the present disclosure will be described with reference tothe accompanying drawings. In the following description, the samecomponents are denoted by the same reference numerals, and descriptionthereof is omitted as appropriate.

Exemplary Embodiment

FIG. 1 is a schematic diagram illustrating a configuration of foammolded article 10 according to an exemplary embodiment. Foam moldedarticle 10 according to the exemplary embodiment includes main agentresin 1, filler 2 of greater than or equal to 15% by mass and less thanor equal to 80% by mass, and a foaming agent of greater than or equal to0.01% by mass and less than or equal to 10% by mass. This foaming agenthas a foaming ratio of greater than or equal to 1.1 times. According tofoam molded article 10, high strength and weight reduction can berealized by including filler 2 having the mass concentration in theabove range and the foaming ratio caused by the foaming agent in theabove range.

Hereinafter, constituent members constituting foam molded article 10will be described.

Main Agent Resin

In the exemplary embodiment, main agent resin 1 is preferably athermoplastic resin in order to ensure excellent moldability. Examplesof the thermoplastic resin include an olefin resin (including a cyclicolefin resin), a styrenic resin, a (meth)acrylic resin, an organic acidvinyl ester resin or a derivative thereof, a vinyl ether resin, ahalogen-containing resin, a polycarbonate resin, a polyester resin, apolyamide resin, a thermoplastic polyurethane resin, a polysulfone resin(such as polyethersulfone, polysulfone), a polyphenylene ether resin(such as a polymer of 2,6-xylenol), a cellulose derivative (such ascellulose esters, cellulose carbamates, and cellulose ethers), asilicone resin (such as polydimethyl siloxane and polymethyl phenylsiloxane), a rubber or an elastomer (dibutadiene rubber such aspolybutadiene and polyisoprene, a styrene-butadiene copolymer, anacrylonitrile-butadiene copolymer, an acrylic rubber, a urethane rubber,and a silicone rubber). The resin may be used alone or two or more typesthereof may be used in combination. Main agent resin 1 is not limited tothe above materials as long as it has thermoplasticity.

Among these thermoplastic resins, main agent resin 1 is preferably anolefin resin having a relatively low melting point. Examples of theolefin resin include a copolymer of olefin monomers, a copolymer of anolefin monomer and other copolymerizable monomers, in addition tohomopolymers of olefin monomers. Examples of the olefin monomer includechain olefins (such as α-C2-20 olefins such as ethylene, propylene,1-butene, isobutene, 1-pentene, 4-methyl-1-pentene, 1-octene); andcyclic olefins These olefin monomers may be used alone or two or moretypes thereof may be used in combination. Among the olefin monomers,chain olefins such as ethylene and propylene are preferable. Examples ofother copolymerizable monomers include fatty acid vinyl esters such asvinyl acetate and vinyl propionate; (meth)acrylic monomers such as(meth)acrylic acid, alkyl (meth)acrylate, glycidyl (meth)acrylate;unsaturated dicarboxylic acids or anhydrides thereof such as maleicacid, fumaric acid, and maleic anhydride; vinyl esters of carboxylicacids (such as vinyl acetate and vinyl propionate); cyclic olefins suchas norbornene and cyclopentadiene; and dienes such as butadiene andisoprene. These copolymerizable monomers may be used alone or two ormore types thereof may be used in combination. Specific examples of theolefin resin include polyethylene (such as low density, medium density,high density, or linear low density polyethylene), polypropylene, anethylene-propylene copolymer, a copolymer of chain olefins (particularlyα-C2-4 olefins) such as terpolymers such as ethylene-propylene-butene-1.

In the exemplary embodiment, the content of main agent resin 1 ispreferably greater than or equal to 10% by mass and less than or equalto 85% by mass. It is more preferably greater than or equal to 15% bymass and less than or equal to 75% by mass, and is still more preferablygreater than or equal to 20% by mass and less than or equal to 65% bymass. When the content of main agent resin 1 is less than 10% by mass,fluidity at the time of pellet molding and foam molding is deteriorated,and molding defects occur. On the other hand, when the content of mainagent resin 1 exceeds 85% by mass, the effect of improving the strengthof the foam molded article due to the addition of fibrous filler 2 isnot able to be obtained.

Dispersant

Next, the dispersant will be described. In this exemplary embodiment, adispersant is contained for the purpose of improving the adhesivenessbetween fibrous filler 2 and main agent resin 1 or the dispersibility offibrous filler 2 in main agent resin 1. Examples of the dispersantinclude various titanate coupling agents, silane coupling agents,unsaturated carboxylic acid, maleic acid, maleic anhydride, or modifiedpolyolefin grafted with anhydrides thereof, fatty acid, fatty acid metalsalt, and fatty acid ester. The silane coupling agent is preferably anunsaturated hydrocarbon type or an epoxy type. There is no problem evenif the surface of the dispersant is treated and modified with athermosetting or thermoplastic polymer component.

The content of the dispersant in the exemplary embodiment is preferablygreater than or equal to 0.01% by mass and less than or equal to 20% bymass, is more preferably greater than or equal to 0.1% by mass and lessthan or equal to 10% by mass, and is still more preferably greater thanor equal to 0.5% by mass and less than or equal to 5% by mass. When thecontent of the dispersant is less than 0.01% by mass, dispersion defectsoccur. On the other hand, when the content of the dispersant exceeds 20%by mass, the strength of the foam molded article is lowered. Thedispersant is appropriately selected depending on the combination ofmain agent resin 1 and filler 2, and may not be added in the case of acombination that does not require the dispersant.

Fibrous Filler

Next, fibrous filler 2 will be described. In this exemplary embodiment,fibrous filler 2 (hereinafter, sometimes simply referred to as “fiber”)is mainly used for the purpose of improving mechanical properties andimproving a dimensional stability due to reduction in a coefficient oflinear expansion in foam molded article 10 molded using a compositeresin composition. For this purpose, fibrous filler 2 preferably has ahigher elastic modulus than an elastic modulus of main agent resin 1,and specific examples thereof include a carbon fiber, a carbon nanotube,a pulp, cellulose, a cellulose nanofiber, lignocellulose, alignocellulose nanofiber, a basic magnesium sulfate fiber (magnesiumoxysulfate fiber), a potassium titanate fiber, an aluminum borate fiber,a calcium silicate fiber, a calcium carbonate fiber, a silicon carbidefiber, wollastonite, zonotlite, various metal fibers, natural fiberssuch as cotton, silk, and wool or hemp, a rejuvenated fiber such as ajute fiber, rayon, or cupra, semi-synthetic fibers such as acetate andpromix, synthetic fibers such as polyester, polyacrylonitrile,polyamide, aramid, and polyolefin, and modified fibers obtained bychemically modifying those surfaces and terminals. Among them, from theviewpoint of availability, high modulus of elasticity, and lowcoefficient of linear expansion, carbons and celluloses are particularlypreferable. From the viewpoint of environmental properties, naturalfibers of celluloses are preferable.

The content (mass concentration) of fibrous filler 2 in the exemplaryembodiment is preferably greater than or equal to 15% by mass and lessthan or equal to 85% by mass. It is more preferably greater than orequal to 20% by mass and less than or equal to 80% by mass, and is stillmore preferably greater than or equal to 30% by mass and less than orequal to 70% by mass. If the content (mass concentration) of fibrousfiller 2 is less than 15% by mass, the effect of improving the strengthof foam molded article 10 due to the addition of fibrous filler 2 is notable to be obtained. On the other hand, when the content (massconcentration) of fibrous filler 2 exceeds 85% by mass, the fluidity atthe time of pellet molding and foam molding is deteriorated, and moldingdefects occur.

FIG. 2 is a schematic view for explaining filler 2 of the exemplaryembodiment. The shape of fibrous filler 2 will be described. Asillustrated in FIG. 2, symbol L is a length of fibrous filler 2(hereinafter, may be referred to as “fiber length”), and symbol d is awidth of fibrous filler 2 (hereinafter, may be referred to as “fiberdiameter”). Fibrous filler 2 is preferably a mixed fiber of fibers 2Ahaving a large aspect ratio (L/d) and fibers 2B having a small aspectratio. If there are many fibers 2A having a large aspect ratio, theelastic modulus is increased. The aspect ratio of fiber 2A is preferablyhigher than or equal to 10. However, the impact resistance deteriorateswhen there are many fibers 2A having a large aspect ratio. Fiberaggregates are increased and the appearance deteriorates. On the otherhand, when there are many fibers 2B having a small aspect ratio, theimpact resistance is improved, and there are few fiber aggregates,resulting in excellent appearance. The aspect ratio of fiber 2B ispreferably less than or equal to 2. However, if there are many fibers 2Bhaving a small aspect ratio, the elastic modulus is decreased.

The relationship between the aspect ratio and the elastic modulus willbe described. At the time of applying a stress to foam molded article10, when there is fiber 2A having a large aspect ratio, even if thefiber is elongated, a fiber with high rigid is difficult to elongate, sothat foam molded article 10 is not distorted. Therefore, the elasticmodulus is increased. On the other hand, in a case of fiber 2B having asmall aspect ratio, at the time of applying the stress, a strainsuppressing effect by the fiber is weakened, and foam molded article 10is strained, and thereby the elastic modulus is decreased.

The relationship between the aspect ratio and the impact resistance willbe described. If there is fiber 2A having a large aspect ratio when theimpact is applied to foam molded article 10, the fiber is not able tofollow the elongation of the resin, and a crack enters between the resinand the fiber, which leads to be broken. On the other hand, in the caseof fiber 2B having a small aspect ratio, since the fiber is fine, thefiber follows the elongation of the resin when the impact is applied tofoam molded article 10, and the crack hardly enters between the resinand the fiber, so that it is not easily broken.

The relationship between the aspect ratio and the appearance will bedescribed. By kneading both fiber 2A having a large aspect ratio andfiber 2B having a small aspect ratio, fiber 2B having a small aspectratio is inserted between the fibers 2A having a large aspect ratio. Theaggregation is suppressed and the appearance is improved.

As described above, it is preferable that fiber 2A having a large aspectratio and fiber 2B having a small aspect ratio are mixed in foam moldedarticle 10 from the viewpoint of the elastic modulus, the impactresistance, and the appearance. The relationship between the mixingratios of the fibers can be calculated by simulation to improve thecharacteristics. Regarding the proportion of each fiber in fibrousfiller 2, it is preferable that the existence ratio of fiber 2A havingan aspect ratio of higher than or equal to 10 is greater than or equalto 1% and less than or equal to 10%, and the existence ratio of thefiber 2B having an aspect ratio of lower than or equal to 2 is greaterthan or equal to 50% and less than or equal to 70%.

The existence ratio of other fibers having an aspect ratio higher than 2and lower than 10 is greater than or equal to 20% and less than or equalto 49%.

Next, the characteristics of fibrous filler 2 will be described. Thekinds of main agent resin 1 and fibrous filler 2 are as described above.If fibrous filler 2 is excessively soft with respect to main agent resin1, that is, if the elastic modulus is small, the composite resincomposition has a low elastic modulus as a whole, resulting in adecrease in strength. On the other hand, if fibrous filler 2 isexcessively hard with respect to main agent resin 1, that is, theelastic modulus is large, the impact wave generated at the time ofimpact is not propagated and is absorbed at the interface between mainagent resin 1 and fibrous filler 2, so that cracks and crazes are likelyto occur near the interface, resulting in a decrease in the impactstrength. Therefore, the relationship between the elastic moduli of mainagent resin 1 and fibrous filler 2 is preferably higher in the elasticmodulus of fibrous filler 2, and the difference is preferably as smallas possible. The optimum relationship is calculated from the simulationresults, and the difference in the elastic modulus between main agentresin 1 and fibrous filler 2 is preferably within 20 GPa.

These fibrous fillers 2 are used for the purpose of improving theadhesiveness with main agent resin 1 or the dispersibility in thecomposite resin composition, and examples thereof include thosesubjected to a surface treatment with various titanate coupling agents,silane coupling agents, unsaturated carboxylic acid, maleic acid, maleicanhydride, or modified polyolefin grafted with anhydrides thereof, fattyacid, fatty acid metal salt, and fatty acid ester. Alternatively, thereis no problem even if those subjected to the surface treatment with athermosetting or thermoplastic polymer component are used.

Foaming agent

Next, the foaming agent will be described. In the exemplary embodiment,the foaming agent is used for the purpose of supplying gas for formingbubbles, that is, foam cells, during foam molding. Here, the foam cellis a hole formed by gas generated by thermal decomposition of a foamingagent or gas generated by a change in solubility of dissolved gas in aresin. The foaming agents are roughly classified into chemical foamingagents and physical foaming agents, but there is no particularlimitation. Examples of the chemical foaming agent include organicchemical foaming agents such as ADCA (azodicarbonamide), DPT(N,N′-dinitropentamethylene hand and lamin), OBSH (4,4′-oxybisbenzenesulfonyl hydrazide), and inorganic chemical foaming agents such asbicarbonates such as sodium bicarbonate, carbonates such as sodiumcarbonate, and a combination of bicarbonate and organic acid salt suchas citrate. These chemical foaming agents may be used alone or two ormore kinds thereof may be used in combination, and foaming aids (such asurea compounds and zinc compounds) may also be used. Examples of thephysical foaming agent include liquefied gases such aschlorofluorocarbon gas, hydrocarbon gas, nitrogen gas, and carbondioxide gas, and supercritical fluids such as nitrogen and carbondioxide.

The content of the foaming agent in the exemplary embodiment ispreferably greater than or equal to 0.01% by mass and less than or equalto 15% by mass. It is more preferably greater than or equal to 0.1% bymass and less than or equal to 10% by mass, and is still more preferablygreater than or equal to 0.5% by mass and less than or equal to 5% bymass. When the content of the foaming agent is less than 0.01% by mass,the foaming nuclei are reduced, and thus the foam cell diameter isincreased, the density variation in foam molded article 10 is increased,and thereby the appearance is deteriorated. On the other hand, when thecontent of the foaming agent exceeds 15% by mass, the strength of thefoam molded article 10 is lowered.

Here, the relationship between the structure of foam molded article 10and the impact resistance will be described. If the elastic modulus ofthe surface layer of foam molded article 10 is high, the rigidity offoam molded article 10 as a whole is enhanced, and when the impact isapplied to foam molded article 10, the impact can be absorbed insidefoam molded article 10 and the impact resistance is improved.

The relationship between the structure of foam molded article and theappearance will be described. The absence of foam cells 3 on the surfaceof foam molded article 10 suppresses the deterioration of the surfaceroughness due to foam cells 3 and improves the appearance.

As described above, from the viewpoint of the impact resistance and theappearance, it is preferable to employ a layer structure in which foammolded article 10 has a high elastic modulus in a surface layer portion,and there is no foam cell 3, and the impact can be absorbed in foammolded article 10, and weight reduction can be realized.

FIG. 3 is a schematic view for explaining skin layer 4, core surfacelayer 5, and a core inner layer 6 of foam molded article 10 of theexemplary embodiment. From the above, as illustrated in FIG. 3, foammolded article 10 in the exemplary embodiment is formed of skin layer 4,core surface layer 5, core inner layer 6, core surface layer 5, and skinlayer 4 in order. Here, the layers having the same name have the samecharacteristics, and the thicknesses of skin layer 4 and core surfacelayer 5 will be described as the thickness of the two layers.

Here, as illustrated in FIG. 3, the thickness of first (upper) skinlayer 4 is set as d_(s1), and the thickness of a second (lower) skinlayer 4 is set as d_(s2). Thickness d_(s) of skin layer 4 of the twolayers included in foam molded article 10 is the total of thicknessd_(s1) of first skin layer 4 and thickness d_(s2) of second skin layer4. Similarly, the thickness of first (upper) core surface layer 5 is setas d_(f1), and the thickness of second (lower) core surface layer 5 isd_(f2). Thickness d_(f) of core surface layer 5 of the two layersincluded in foam molded article 10 is the total of thickness d_(f1) offirst core surface layer 5 and thickness d_(f2) of second core surfacelayer 5.

Skin Layer

The skin layer 4 is a layer that does not have foam cell 3, a massconcentration ratio (amount of fibrous filler in skin layer/amount offibrous filler in core inner layer) of the amount of fibrous filler 2 inskin layer 4 and core inner layer 6 is preferably greater than or equalto 1.05 and less than or equal to 1.6. The ratio (skin layer thicknessd_(s)/foam molded article thickness d_(a)) of the thickness of skinlayer 4 to the thickness of the entire foam molded article 10 ispreferably greater than or equal to 0.01 and less than or equal to 0.5.

When skin layer 4 has foam cells 3, the appearance defects occur, thesurface elastic modulus is insufficient, and the impact resistance isreduced. When the mass concentration ratio of the amount of fibrousfiller 2 of skin layer 4 to the amount of fibrous filler 2 of core innerlayer 6 is less than 1.05, the elastic modulus of the surface of foammolded article 10 is insufficient and the impact resistance isdeteriorated. In a case where the ratio of the amount of fibrous filler2 in skin layer 4 to the amount of fibrous filler 2 of core inner layer6 exceeds 1.6, since the strength difference between the layers of foammolded article 10 is increased, the shock wave generated at the time ofimpact does not follow, and cracks and the like are likely to enter,thereby deteriorating the impact resistance.

When the ratio (skin layer thickness d_(s)/foam molded article thicknessd_(a)) of the thickness of skin layer 4 to the thickness of foam moldedarticle 10 is less than 0.01, the elastic modulus of the surface isinsufficient and the impact resistance is deteriorated; on the otherhand, when it exceeds 0.5, the overall density is affected, and therebyweight reduction is not able to be realized.

Core Surface Layer

Next, core surface layer 5 will be described. Core surface layer 5 is alayer including foam cell 3, a mass concentration ratio (fibrous filleramount in the skin layer/fibrous filler amount in the core inner layer)of the amount of fibrous filler 2 in core surface layer 5 and core innerlayer 6 is greater than or equal to 1.02 and less than or equal to 1.5,and a ratio (core surface layer thickness d_(f)/foam molded articlethickness d_(a)) of the thickness of core surface layer 5 to thethickness of foam molded article 10 is greater than or equal to 0.01 andless than or equal to 0.5, and a diameter of foam cell 3 in core surfacelayer 5 is preferably smaller than or equal to 80 μm. Core surface layer5 is an intermediate layer between skin layer 4 and core inner layer 6,and reduces the strength difference between skin layer 4 and core innerlayer 6 so as to improve the impact resistance. Therefore, core surfacelayer 5 preferably has an intermediate strength between skin layer 4 andcore inner layer 6. When the foam cell diameter of core surface layer 5exceeds 80 μm, since the strength difference with skin layer 4 ispartially increased, the shock wave generated at the time of impact doesnot follow, and cracks and the like are likely to enter, therebydeteriorating the impact resistance. When the mass concentration ratioof the amount of fibrous filler 2 of core surface layer 5 to the amountof fibrous filler 2 of core inner layer 6 is less than 1.02, the elasticmodulus of the surface of foam molded article 10 is insufficient and theimpact resistance is deteriorated. In a case where the massconcentration ratio of the amount of fibrous filler 2 in core surfacelayer 5 to the amount of fibrous filler 2 of core inner layer 6 exceeds1.5, since the strength difference between the layers of foam moldedarticle 10 is increased, the shock wave generated at the time of impactdoes not follow, and cracks and the like are likely to enter, therebydeteriorating the impact resistance.

When the ratio (core surface layer thickness d_(f)/foam molded articlethickness d_(a)) of the thickness of core surface layer 5 to thethickness of foam molded article 10 is less than 0.01, the elasticmodulus of the surface is insufficient and the impact resistance isdeteriorated; on the other hand, when it exceeds 0.5, the overalldensity is affected, and thereby weight reduction is not able to berealized.

Core Inner Layer

Next, core inner layer 6 in the exemplary embodiment will be described.Core inner layer 6 is a layer having foam cells 3, and the foam celldiameter in core inner layer 6 is preferably smaller than or equal to500 μm. When the cell diameter of core inner layer 6 exceeds 500 μm,cracks and the like are likely to enter from the location where the foamcell diameter is large, thereby deteriorating the impact resistance.

Method of Producing Foam Molded Article

Next, a method of producing foam molded article 10 will be described.FIG. 4 is a flowchart of the method of producing foam molded article 10according to the exemplary embodiment. (1) First, main agent resin 1,fibrous filler 2, and a dispersant as necessary are put into amelt-kneading apparatus and the mixture is melt-kneaded in theapparatus. As a result, main agent resin 1 is melted, and fibrous filler2 and the dispersant are dispersed in molten main agent resin 1. At thesame time, due to a shearing action of the apparatus, defibration ofaggregates of fibrous filler 2 is promoted, and fibrous filler 2 can befinely dispersed in main agent resin 1.

In the related art, as fibrous filler 2, those obtained by defibratingfillers in advance by pretreatment such as wet dispersion have beenused. However, when fibrous filler 2 is defibrated in advance in asolvent used for wet dispersion, since it is easy to be defibrated ascompared with a case of being defibrated in the melted main agent resin1, it is difficult to defibrate only the ends, and entire fibrous filler2 may be defibrated. In addition, there was a problem that the number ofsteps was increased by adding the pretreatment, and the productivity wasdeteriorated.

On the other hand, in the producing process of the foam molded articlein the exemplary embodiment, a melt-kneading treatment (total drymethod) is performed together with main agent resin 1 and the dispersantwithout the pretreatment by wet dispersion for the purpose of adefibration treatment and a modification treatment of fibrous filler 2.In this method, since the wet dispersion treatment of fibrous filler 2is not performed, as described above, only the end portion of fibrousfiller 2 can be defibrated, and the number of steps can be reduced toimprove the productivity.

In order to produce the composite resin composition in the exemplaryembodiment by the total dry method, it is preferable that high shearstress is applied during kneading, and specific examples of kneadingmeans include methods with a single-screw kneader, a twin-screw kneader,a roll kneader, and a Banbury mixer. From the viewpoint of easyapplication of high shear and high productivity, continuous biaxialkneaders and continuous roll kneaders are particularly preferred. Thekneading means other than the above may be used as long as it can applya high shear stress.

(2) The composite resin composition extruded from a melt-kneader is madeinto a pellet shape through a cutting step by a pelletizer or the like.Examples of a method of pelletization, as a method to be performedimmediately after melting the resin, include an aerial hot cut method,an underwater hot cut method, and a strand cut method. Alternatively,there is a pulverization method in which a molded article or sheet isonce formed and then pulverized and cut.

(3) In a case of using a chemical foaming agent, an injection moldedproduct as foam molded article 10 can be produced by dry blending thepellets and the chemical foaming agent before injection foam molding andthen performing the injection foam molding. In a case of using aphysical foaming agent, an injection molded product as a foam moldedarticle can be produced by injecting the above pellets into an injectionfoam molding machine, injecting the physical foaming agent aftermelting, and performing the injection foam molding. Hereinafter, eachexample and each comparative example in the experiment conducted by thepresent inventors will be described.

EXAMPLE 1

A pulp-dispersed polypropylene composite foam molded article wasproduced by the following production method.

Softwood pulp (trade name: NBKP Celgar, manufactured by Mitsubishi PaperMills Limited.) was used as a starting material for the fibrous filler.This softwood pulp was pulverized with a pulverizer to obtain a mixtureof fillers with different fibrous filler aspect ratios. Each aspectratio was adjusted in the grinding process. Polypropylene as the mainagent resin (trade name: J108M, prepared by Prime Polymer Co., Ltd.),the fibrous filler, and maleic anhydride as a dispersant (trade name:Yumex, prepared by Sanyo Chemical Industries, Ltd.) were weighed to aweight ratio of 42:50:5 and were dry blended. Thereafter, the mixturewas melt-kneaded and dispersed with a twin-screw kneader (KRC Kneadermanufactured by Kurimoto, Ltd.). The resin melt was hot-cut to produce apulp-dispersed polypropylene pellet.

The produced pulp-dispersed polypropylene pellet and polyslen as afoaming agent (prepared by Eiwa Chemical Ind. Co., Ltd.) were weighed toa weight ratio of 97:3 and were dry blended. Thereafter, a test piece ofa foam molded article was produced using an injection foam moldingmachine (180AD, manufactured by The Japan Steel Works, Ltd.) using acore back method at a foaming ratio of 1.6 times. The test piece wasprepared under the following manufacturing conditions: resin temperatureof 190° C., mold temperature of 40° C., injection speed of 100 mm/s, andholding pressure of 60 MPa. Each layer structure was adjusted by aninjection foaming process and a material composition. The pellet andfoaming agent were bitten into the screw of the molding machine througha hopper, and the penetration at that time was measured by the amount ofpellet decrease per hour, and as a result, it was confirmed to beconstant. The shape of the test piece was changed according to theevaluation items described below, and a No. 1 size dumbbell wasmanufactured for measuring the elastic modulus. A foam molded articlewith 60 mm square and a thickness of 1.6 mm was manufactured for a dropimpact test and for appearance confirmation. In addition, in order toevaluate the foaming ratio, a composite resin molded article was alsomanufactured from the above flat plate not subjected to foam molding.The obtained pulp-dispersed polypropylene composite foam molded articletest piece was evaluated by the following method.

Foaming Ratio

The foaming ratio was measured from the ratio of the apparent density ofa test piece of the obtained flat foam molded article and a test pieceof a molded article not foamed. Here, as an evaluation method of theapparent density, the volume was calculated from the measurement resultof the molded article size with calipers, and the apparent density wascalculated from the result of the weight measured with a precisionbalance so as to calculate the ratio. As a result of evaluating thefoaming ratio, it was 1.61 times.

Foam Cell Diameter

The cross section of the obtained pulp-dispersed polypropylene compositefoam molded article was exposed by a CP treatment, and the foam celldiameter was observed by SEM observation. As a result of measuring about10 typical foam cells in the core surface layer and the core innerlayer, the maximum diameter of foam cell 3 in the core surface layer was50 μm, and the diameter of foam cell 3 in the core inner layer was 250μm.

Pulp Amount

The cross section of the obtained pulp-dispersed polypropylene compositefoam molded article was exposed by a CP treatment, and the peakintensity of 3400 cm−1 was evaluated by infrared spectroscopy. The ratioof the skin layer to the core inner layer was 1.2. The ratio of the coresurface layer to the core inner layer was 1.15.

Aspect Ratio of Fiber

The obtained pulp-dispersed polypropylene pellet was immersed in axylene solvent to dissolve the polypropylene, and the shape of theremaining pulp fibers was observed by SEM. As a result of measuringabout 50 representative fibers and five places, the ratio of aspectratio of higher than or equal to 10 was greater than or equal to 5% andless than or equal to 10%, and the ratio of aspect ratio of lower thanor equal to 2 was greater than or equal to 50% and less than or equal to60%.

Elastic Modulus of Foam Molded Article

A tensile test was carried out using the obtained No. 1 dumbbell-shapedtest piece. Here, as the evaluation method of the elastic modulus, thenumerical value of less than 1.6 GPa was evaluated as D, the value ofgreater than or equal to 1.6 GPa and less than 2.0 GPa was evaluated asB, and the value of greater than or equal to 2.0 GPa was evaluated as A.The elastic modulus of the test piece was 2.5 GPa, and was evaluated asA.

Drop Impact Test of Foam Molded Article

A drop impact test was carried out using the obtained flat test piece.Specifically, a 250 g weight pyramid was dropped from a height of 80 cmtoward the plate surface of the test piece to confirm whether cracksenter or not. As this evaluation method, a case where no crack wasconfirmed was marked as B, a case where cracks were found only on thesurface, and the length of the crack was less than 10 mm was marked asC, and a case where the crack which penetrated was confirmed or thelength of the crack was greater than or equal to 10 mm was marked as D.The test piece was not cracked, and evaluated as B.

Weight Reduction Rate

The specific rigidity was calculated from the results of the apparentdensity and the elastic modulus at the time of foaming ratiocalculation, and the weight reduction rate was calculated from the ratioof the aforementioned specific rigidity to the specific rigidity ofpolypropylene simple substance. Here, as the evaluation method of theweight reduction rate, the numerical value of less than 15% wasevaluated as D, the value of greater than or equal to 15% and less than20% was evaluated as B, and the value of greater than or equal to 20%was evaluated as A. As a result of calculating the weight reductionrate, it was 32% and evaluated as A.

Appearance of Foam Molded Article

Sensory evaluation was performed to determine whether a visible level offiber agglomerates appeared as white spots or bubbles were visible onthe foam molded article. A foam molded article without traces of thewhite spots or the bubbles was marked as B, and a case where the tracesof the white spots or the bubbles were present or the traces of thewhite spots or the bubbles had been present was marked as C.

EXAMPLE 2

In Example 2, a pulp-dispersed polypropylene pellet and a foam moldedarticle were produced under the same material conditions and processconditions as in Example 1 except that polypropylene, a cotton-likesoftwood pulp, and maleic anhydride were weighed to be 62:30:5 at aweight ratio, and dry blended, and a target foaming ratio was changed to1.8 times. Regarding the evaluation, the same evaluation as in Example 1was performed.

EXAMPLE 3

In Example 3, a pulp-dispersed polypropylene pellet and a foam moldedarticle were produced under the same material conditions and processconditions as in Example 1 except that polypropylene, a cotton-likesoftwood pulp, and maleic anhydride were weighed to be 22:70:5 at aweight ratio, and dry blended, and a target foaming ratio was changed to1.3 times, the pulp-dispersed polypropylene pellet and the polyslene wasweighed to be 99:1 at a weight ratio. Regarding the evaluation, the sameevaluation as in Example 1 was performed.

EXAMPLE 4

In Example 4, a pulp-dispersed polypropylene pellet and a foam moldedarticle were produced under the same material conditions and processconditions as in Example 1 except that pulp pulverization time waschanged to be longer. Regarding the evaluation, the same evaluation asin Example 1 was performed.

EXAMPLE 5

In Example 5, a pulp-dispersed polypropylene pellet and a foam moldedarticle were produced under the same material conditions and processconditions as in Example 1 except that pulp pulverization time waschanged to be shorter. Regarding the evaluation, the same evaluation asin Example 1 was performed.

COMPARATIVE EXAMPLE 1

In Comparative Example 1, a pulp-dispersed polypropylene pellet and afoam molded article were produced under the same material conditions andprocess conditions as in Example 1 except that polypropylene, acotton-like softwood pulp, and maleic anhydride were weighed to be82:10:5 at a weight ratio, and dry blended, and a target foaming ratiowas changed to 1.6 times. Regarding the evaluation, the same evaluationas in Example 1 was performed.

COMPARATIVE EXAMPLE 2

In Comparative Example 2, a pulp-dispersed polypropylene pellet and afoam molded article were produced under the same material conditions andprocess conditions as in Example 1 except that polypropylene, acotton-like softwood pulp, and maleic anhydride were weighed to be22:70:5 at a weight ratio, and dry blended, and a target foaming ratiowas changed to 1.05 times, the pulp-dispersed polypropylene pellet andthe polyslene were weighed to be 99.995:0.005 at a weight ratio.Regarding the evaluation, the same evaluation as in Example 1 wasperformed.

COMPARATIVE EXAMPLE 3

In Comparative Example 3, a pulp-dispersed polypropylene pellet and afoam molded article were produced under the same material conditions andprocess conditions as in Example 1 except that polypropylene, acotton-like softwood pulp, and maleic anhydride were weighed to be22:70:5 at a weight ratio, and dry blended, and a target foaming ratiowas changed to 1.05 times. Regarding the evaluation, the same evaluationas in Example 1 was performed.

The measurement results in Examples 1 to 5 and Comparative Examples 1 to3 are illustrated in FIG. 5.

As is clear from FIG. 5, Example 2 in which the amount of fibrous fillerwas decreased and the foaming ratio was increased resulted in a slightlyinferior elastic modulus; however, the effects of the skin layer andcore surface layer caused the deterioration of the impact resistance tobe suppressed. On the contrary, Example 3 in which the amount of fibrousfiller was increased and the foaming ratio was decreased resulted inslightly inferior weight reduction; however, the fibrous fillers withdifferent aspect ratios were mixed and the skin layer did not have foamcells, which caused the deterioration of the appearance to besuppressed. In Example 4 in which the amount of the fibrous fillerhaving an aspect ratio of 10 was reduced, the elastic modulus wasslightly reduced, but it was confirmed that there was no problem. It wasconfirmed that if greater than or equal to 10% by mass and less than orequal to 85% by mass of the main agent resin, greater than or equal to15% by mass and less than or equal to 85% by mass of the filler, greaterthan or equal to 0.01% by mass and less than or equal to 20% by mass ofthe dispersant, and greater than or equal to 0.01% by mass and less thanor equal to 15% by mass of the foaming agent were contained, and thefoaming ratio was greater than or equal to 1.1 times, a foam moldedarticle with both high strength and weight reduction was obtained.

In Comparative Example 1 where the amount of fibrous filler was reducedto 10%, the elastic modulus was insufficient due to the small amount ofthe fibrous filler. Since the fibrous filler also acted as a foamnucleating agent, the diameter of foam cell 3 was also increased. As aresult, the impact resistance was decreased and cracks occurred in theimpact test.

In Example 5 where the proportion of fibers having an aspect ratio ofthe fibrous filler higher than or equal to 10 was increased, while theelastic modulus was slightly higher, the impact resistance was reducedand cracks occurred in the impact test. The white spots were observed inthe foam molded article due to aggregation of fibers having a largeaspect ratio.

In Comparative Example 2 in which the amount of the foaming agent wasreduced to 0.005%, the foaming ratio was lower than the target foamingratio. Due to very small amount of the foaming agent that become as afoam core, the foam cell diameter was increased, and thus there is noproblem in the elastic modulus. However, uniformity and the impactresistance were deteriorated, and cracks occurred in the impact test.

In Comparative Example 3 in which the foaming ratio was reduced to 1.05,due to the small foaming ratio, there was no problem in the elasticmodulus and the impact resistance, but the weight reduction was not ableto be achieved.

From the above evaluation, when the composite resin composition in thefoam molded article contains greater than or equal to 10% by mass andless than or equal to 85% by mass of the main agent resin, greater thanor equal to 15% by mass and less than or equal to 85% by mass of thefiller, greater than or equal to 0.01% by mass and less than or equal to15% by mass of the foaming agent, and the foaming ratio caused by thefoaming agent was greater than or equal to 1.1 times, the high strengthand the weight reduction can be realized. It was found that when theexistence ratio of the fiber having an aspect ratio of the further addedfibrous filler, higher than or equal to 10 was greater than or equal to1% and less than or equal to 10%, and the existence ratio of the fiberhaving an aspect ratio of lower than or equal to 2 was greater than orequal to 50% and less than or equal to 70%, a foam molded article havingexcellent appearance without fiber aggregates can be obtained.

Note that, the present disclosure includes appropriate combinations ofany exemplary embodiment and/or example among the above-describedvarious exemplary embodiments and/or examples, and exhibits an effect ofeach exemplary embodiment and/or example.

As described above, according to the foam molded article of the presentdisclosure, both high impact resistance and weight reduction can beachieved, and an excellent appearance can be realized.

According to the foam molded article of the present disclosure, it ispossible to provide a foam molded article that is excellent in themechanical strength as compared with the general-purpose resin in therelated art.

According to the present disclosure, since the properties of the mainagent resin can be improved, it can be used as an alternative toengineering plastics or an alternative to metallic materials. Therefore,the manufacturing cost of various industrial products made ofengineering plastics or metals, or daily necessities can be greatlyreduced. It can also be used for home appliance casings, buildingmaterials, and automotive parts.

What is claimed is:
 1. A foam molded article comprising: a main agentresin; a filler of greater than or equal to 15% by mass and less than orequal to 80% by mass; and a foaming agent of greater than or equal to0.01% by mass and less than or equal to 10% by mass, wherein a foamingratio caused by the foaming agent is 1.1 times or more.
 2. The foammolded article of claim 1, further comprising: a skin layer positionedon a surface; a core surface layer positioned inside the skin layer andhaving a lower mass concentration of the filler than a massconcentration of the skin layer; and a core inner layer positionedinside the core surface layer and having a lower mass concentration ofthe filler than a mass concentration of the core surface layer.
 3. Thefoam molded article of claim 2, wherein a ratio of a mass concentrationof the filler in the skin layer to a mass concentration of the filler inthe core inner layer is greater than or equal to 1.05, and a ratio ofthe mass concentration of the filler in the core surface layer withrespect to the mass concentration of the filler in the core inner layeris greater than or equal to 1.02.
 4. The foam molded article of claim 2,wherein a cell diameter of the foaming agent contained in the coresurface layer is smaller than a cell diameter of the foaming agentcontained in the core inner layer.
 5. The foam molded article of claim4, wherein the cell diameter of the foaming agent contained in the coresurface layer is greater than or equal to 40 μm and smaller than orequal to 80 μm, and the cell diameter of the foaming agent contained inthe core inner layer is greater than or equal to 90 μm and smaller thanor equal to 500 μm.
 6. The foam molded article of claim 1, wherein thefiller includes a filler having an aspect ratio of lower than or equalto 2 and a filler having an aspect ratio of higher than or equal to 10.7. The foam molded article of claim 6, wherein in the filler, aproportion of the filler having an aspect ratio of higher than or equalto 2 is higher than a proportion of the filler having an aspect ratio ofhigher than or equal to
 10. 8. The foam molded article of claim 7,wherein the proportion of the filler having an aspect ratio of lowerthan or equal to 2 in the fillers is greater than or equal to 50% andless than or equal to 70%, and the proportion of the filler having anaspect ratio of higher than or equal to 10 in the fillers is greaterthan or equal to 1% and less than or equal to 10%.